Impact Tool

ABSTRACT

A tool comprising a super hard material is bonded to a cemented metal carbide substrate at a non-planar interface. A cemented metal carbide substrate is bonded to a front end of a cemented metal carbide bolster. The carbide bolster is secured against an outer surface of a drum through a press fit.

CROSS REFERENCE TO RELATED APPLICATIONS

This application is a continuation-in-part of U.S. patent applicationSer. No. 11/971,965 which is a continuation of U.S. patent applicationSer. No. 11/947,644, which was a continuation-in-part of U.S. patentapplication Ser. No. 11/844,586. U.S. patent application Ser. No.11/844,586 is a continuation-in-part of U.S. patent application Ser. No.11/829,761. U.S. patent application Ser. No. 11/829,761 is acontinuation-in-part of U.S. patent application Ser. No. 11/773,271.U.S. patent application Ser. No. 11/773,271 is a continuation-in-part ofU.S. patent application Ser. No. 11/766,903. U.S. patent applicationSer. No. 11/766,903 is a continuation of U.S. patent application Ser.No. 11/766,865. U.S. patent application Ser. No. 11/766,865 is acontinuation-in-part of U.S. patent application Ser. No. 11/742,304.U.S. patent application Ser. No. 11/742,304 is a continuation of U.S.patent application Ser. No. 11/742,261. U.S. patent application Ser. No.11/742,261 is a continuation-in-part of U.S. patent application Ser. No.11/464,008. U.S. patent application Ser. No. 11/464,008 is acontinuation-in-part of U.S. patent application Ser. No. 11/463,998.U.S. patent application Ser. No. 11/463,998 is a continuation-in-part ofU.S. patent application Ser. No. 11/463,990. U.S. patent applicationSer. No. 11/463,990 is a continuation-in-part of U.S. patent applicationSer. No. 11/463,975. U.S. patent application Ser. No. 11/463,975 is acontinuation-in-part of U.S. patent application Ser. No. 11/463,962.U.S. patent application Ser. No. 11/463,962 is a continuation-in-part ofU.S. patent application Ser. No. 11/463,953. The present application isalso a continuation-in-part of U.S. patent application Ser. No.11/695,672. U.S. patent application Ser. No. 11/695,672 is acontinuation-in-part of U.S. patent application Ser. No. 11/686,831. Allof these applications are herein incorporated by reference for all thatthey contain.

BACKGROUND OF THE INVENTION

Formation degradation, such as asphalt milling, mining, or excavating,may result in wear on attack tools. Consequently, many efforts have beenmade to extend the life of these tools.

U.S. Pat. No. 3,830,321 to McKenry et al., which is herein incorporatedby reference for all that it contains, discloses an excavating tool anda bit for use therewith in which the bit is of small dimensions and ismounted in a block in which the bit is rotatable and which block isconfigured in such a manner that it can be welded to various types ofholders so that a plurality of blocks and bits mounted on a holder makean excavating tool of selected style and size.

U.S. Pat. No. 6,102,486 to Briese, which is herein incorporated byreference for all that it contains, discloses a frustum cutting inserthaving a cutting end and a shank end and the cutting end having acutting edge and inner walls defining a conical tapered surface. Firstwalls in the insert define a cavity at the inner end of the inner wallsand second walls define a plurality of apertures extending from thecavity to regions external the cutting insert to define a powder flowpassage from regions adjacent the cutting edge, past the inner walls,through the cavity and through the apertures.

U.S. Pat. No. 4,944,559 to Sionnet et al., which is herein incorporatedby reference for all that it contains, discloses a body of a toolconsisting of a single-piece steel component. The housing for thecomposite abrasive component is provided in this steel component. Theworking surface of the body has, at least in its component-holder part,and angle at the lower vertex of at least 20% with respect to the angleat the vertex of the corresponding part of a metallic carbide tool forworking the same rock. The surface of the component holder is at leastpartially covered by an erosion layer of hard material.

U.S. Pat. No. 5,873,423 to Briese, which is herein incorporated byreference for all that it contains, discloses a frustum cutting bitarrangement, including a shank portion for mounting in, and to beretained by, a rotary cutting tool body, the shank portion having anaxis, an inner axial end, and an outer axial end. A head portion has anaxis coincident with the shank portion axis, a front axial end, and arear axial end, the rear end coupled to the shank portion outer end, andthe front end having a conical cavity therein diminishing in diameterfrom the front end toward the rear end. A frustum cutting insert has anaxis coincident with the head portion axis, a forward axial end, a backaxial end, and an outer conical surface diminishing in diameter from theforward end toward the back end, the conical cavity in a taper lock. Invariations of the basic invention, the head portion may be rotatablewith respect to the shank portion, the frustum cutting insert maycomprise a rotating cutter therein, and combinations of such featuresmay be provided for different applications.

BRIEF SUMMARY OF THE INVENTION

In one aspect of the invention, a tool comprising a super hard materialis bonded to a cemented metal carbide substrate at a non-planarinterface. A cemented metal carbide substrate is bonded to a front endof a cemented metal carbide bolster. The carbide bolster is securedagainst an outer surface of a drum through a press fit.

The carbide substrate at the interface may comprise a tapered surfacestarting from a cylindrical rim of the substrate and ending at anelevated flatted central region formed in the substrate. The flattedregion may comprise a diameter of 0.125 to 0.250 inches. The bolster maycomprise a stem with a diameter of 0.250 to 1.00 inches. The stem maycomprise a length of 35 to 100 percent of the length of the bolster. Thedrum may comprise a lug adapted to attach to the bolster. The lug may bethreadedly attached to the drum and the carbide bolster. The lug may bepress-fit into the carbide bolster. The lug may comprise a hydraulicpump adapted to move the lug and lock the carbide bolster against thedrum. The carbide bolster may comprise a base end with a complimentarysurface to that of the outer surface of the drum. The carbide bolstermay be interlocked together. The carbide bolster may be interlockedthrough at least one flat. The carbide bolster may also comprise a stemthat is adapted to be press-fit into the drum. The carbide bolster maycomprise at least one bore opposite the front end. The bore may also betapered. The super hard material may comprise a substantially conicalsurface with a side which forms a 35 to 55 degree angle with a centralaxis of the impact tool. The impact tool may be attached to a millingmachine, a mining machine, a trenching machine, or a combinationthereof.

In another aspect of the invention a high-impact resistant toolcomprises a super hard material bonded to a cemented metal carbidesubstrate at a non-planar interface. The cemented metal carbidesubstrate is bonded to a front end of a cemented metal carbide bolster.The metal carbide bolster comprises a locking mechanism adapted toattach to a drum.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a cross-sectional diagram of an embodiment of a plurality oftools.

FIG. 1 a is cross-sectional diagram of an embodiment of a tool.

FIG. 1 b is another cross-sectional diagram of an embodiment of a tool.

FIG. 1 c is another cross-sectional diagram of an embodiment of a tool.

FIG. 1 d is another cross-sectional diagram of an embodiment of a tool.

FIG. 2 is another cross-sectional diagram of an embodiment of aplurality of tools disposed on a drum.

FIG. 3 is another cross-sectional diagram of an embodiment of aplurality of tools disposed on a drum.

FIG. 4 is a top perspective diagram of an embodiment of a plurality oftools.

FIG. 5 is another top perspective diagram of an embodiment of aplurality of tools.

FIG. 6 is another top perspective diagram of an embodiment of aplurality of tools.

FIG. 7 is a cross-sectional diagram of an embodiment of a tool disposedon a surface.

FIG. 8 is another cross-sectional diagram of an embodiment of a tooldisposed on a surface.

FIG. 9 is another cross-sectional diagram of an embodiment of a tooldisposed on a surface.

FIG. 10 is another cross-sectional diagram of an embodiment of a tooldisposed on a surface.

FIG. 11 is another cross-sectional diagram of an embodiment of a tooldisposed on a surface.

FIG. 12 is another cross-sectional diagram of an embodiment of a tooldisposed on a surface.

FIG. 13 is another cross-sectional diagram of an embodiment of a tool.

FIG. 14 is another cross-sectional diagram of an embodiment of a tooldisposed on a surface.

FIG. 15 is another cross-sectional diagram of an embodiment of a tooldisposed on a surface.

FIG. 16 is another cross-sectional diagram of an embodiment of a tooldisposed on a roller.

FIG. 17 is another cross-sectional diagram of another embodiment of atool disposed on a roller.

FIG. 18 is another cross-sectional diagram of an embodiment of a tool.

FIG. 19 is another cross-sectional diagram of an embodiment of a tooldisposed on a degradation machine.

FIG. 20 is another cross-sectional diagram of an embodiment of a tooldisposed on a rotary device.

FIG. 21 is a cross-sectional diagram of an embodiment of a tool disposedon a percussion bit.

FIG. 22 is another cross-sectional diagram of an embodiment of a tooldisposed on a percussion bit.

FIG. 23 is another cross-sectional diagram of a plurality of tools.

FIG. 24 is another cross-sectional diagram of a plurality of tools.

FIG. 25 is another cross-sectional diagram of a tool.

FIG. 26 is another cross-sectional diagram of a plurality of tools.

FIG. 27 is another cross-sectional diagram of a plurality of tools.

DETAILED DESCRIPTION OF THE INVENTION AND THE PREFERRED EMBODIMENT

FIG. 1 is a cross-sectional diagram of an embodiment of a plurality oftools 101 attached to a driving mechanism, such as rotating drum 103,connected to the underside of a pavement recycling machine 100. Therecycling machine 100 may be a cold planer used to degrade man-madeformations such as a paved surface 104 prior to the placement of a newlayer of pavement. Impact tools 101 may be attached to the drivingmechanism bringing the impact tools 101 into engagement with theformation 104.

FIG. 1 a is a cross-sectional diagram of an embodiment of a tool 101.The tool 101 may comprise a super hard material 202 bonded to a cementedmetal carbide substrate 701 at a non-planar interface 130. The substrate701 at the interface 130 may comprise a tapered surface 702 startingfrom a cylindrical rim 703 of the substrate 701 and ending at anelevated flatted central region formed in the substrate 701. Thecemented metal carbide substrate 701 may be bonded to a front end 705 ofa cemented metal carbide bolster 203. The carbide substrate 701 may bebrazed to a superhard material 202. Super hard material which maycomprise diamond, polycrystalline diamond with a binder concentration of1 to 40 weight percent, cubic boron nitride, refractory metal bondeddiamond, silicon bonded diamond, layered diamond, infiltrated diamond,thermally stable diamond, natural diamond, vapor deposited diamond,physically deposited diamond, diamond impregnated matrix, diamondimpregnated carbide, monolithic diamond, polished diamond, coursediamond, fine diamond, nonmetal catalyzed diamond, cemented metalcarbide, chromium, titanium, aluminum, tungsten, or combinationsthereof. The super hard material may be a polycrystalline structure withan average grain size of 10 to 100 microns. The carbide bolster 203 mayalso comprise at least one cavity 302 formed in its base end 151. Thecavity 302 may comprise a section with a uniform diameter 150 which maybe capable of receiving a shank in a press-fit arrangement.

The inside surface 160 of the cavity 302 may comprise a section thattapers inward towards a central axis 165 of the tool 101. The cavity 302may comprise a closed end 166 with a portion 152 of the cavitycomprising a widened diameter 161. The cavity 152 may comprise a lip153, such as shown in FIGS. 1 b-1 c. The cavity 302 may also comprisethreads 154, such as shown in FIG. 1 d. The base end 151 may comprise aflat geometry, a concave geometry, a convex geometry or combinationsthereof.

FIG. 2 is another cross-sectional diagram of an embodiment of aplurality of tools 101 disposed on a drum 103. The tools 101 maycomprise a stem 200 adapted to attach within a groove 201 in the drum103 such as through a press-fit, or a braze. The impact tools 101 may bespaced less than an inch apart from one another around the drum 103. Insome embodiments of the present invention, the bolster actually contacteach other. The metal carbide bolster 203 may be in contact with theouter surface 204 of the drum 103.

FIG. 3 is another cross-sectional diagram of an embodiment of aplurality of tools 101 disposed on a drum 103. In this embodiment, thedrum 103 comprises a plurality of lugs 301 extending from the outersurface of the drum. The distal end of the lugs fit into the cavitiesfor attachment. The cavities may be press fit, bonded or threaded ontothe lugs. The lugs may be welded to the outer surface 204 of the drum.In a preferred embodiment, the tools are closely packed together suchthat the outer surface of the drum is completely covered or at leastouter surfaces exposed surface is greatly minimized compared totraditional milling machines. In such embodiments, the outer surface ofthe drum is protected from the erosive action of cutting into anyformation.

One such advantage to the embodiments shown in FIGS. 2 and 3 is theirsimplicity. In traditional milling applications blocks or holders arewelded onto the drums and picks are secured within them. In the presentembodiments, holders are not necessary and the abrasion resistantdiamond enhanced carbide bolsters are closer to the surface of the drum,which reduced the bending moment typically experienced in traditionalmilling. Since only wear resistant parts of the tools are exposed to theabrasive nature of milling, the problems with blocks or holders erodingaway are negated.

FIG. 4 is a top perspective diagram of an embodiment of a plurality ofimpact tools 101. The impact tools 101 may comprise a super hardmaterial 202 and a metal carbide bolster 203. The impact tools 101 maycomprise a hexagonal geometry 400. The impact tool may interlock throughat least one flat 401 formed in on the side of the bolster. By packingthe bolsters close together, exposure to the outer surface of the drumin minimized. Also, by placing the bolsters so close together thebolster may support one another when they engage the formation.

FIG. 5 is another top perspective diagram of an embodiment of aplurality of tools 101. The tools 101 may comprise a square geometry 500and may interlock through at least one flat 401. FIG. 6 is another topperspective diagram of an embodiment of a plurality of impact tools 101.The impact tools 101 may comprise at least one flat 401 and mayinterlock through at least one flat 401. The impact tools 101 may alsocomprise at least one rounded side 601. The impact tools 101 may also bedisposed in a “V” formation on a drum (not shown).

FIG. 7 is a cross-sectional diagram of an embodiment of an impact tooldisposed on a portion of a drum 103. The carbide bolster 203 may alsocomprise at least one bore 302 and may be secured against the drum 103by a ring 700 through a press fit. The ring 700 may be bolted to thedrum 103.

FIG. 8 is another cross-sectional diagram of an embodiment of an impacttool 101 disposed on a portion of a drum 103. The drum may comprise aplurality of grooves 201 adapted to receive a middle stem 800 and atleast one outer stem 801 of the carbide bolster 203. The outer stem 801may be shorter in length and width relative to the middle stem 800. Theouter stem 801 may comprise a concave geometry, and the middle stem maycomprise a rectangular geometry.

FIG. 9 is another cross-sectional diagram of an embodiment of an impacttool 101 disposed on a portion of a drum 103. The carbide bolster 203may also comprise one middle stem 800 and may be secured against thedrum 103 through a press fit. The base end 151 of the of the carbidebolster 203 may comprise a complimentary geometry to that of the drum103.

FIG. 10 is another cross-sectional diagram of an embodiment of a tool101 disposed on a portion of a drum 103. The drum 103 may comprise a lug301 that may be threadedly attached to the drum 103. The lug 301 mayalso be threadedly attached to the carbide bolster 203 of the tool 101.

FIG. 11 is another cross-sectional diagram of an embodiment of an impacttool 101 disposed on a portion of a drum 103. The drum 103 may comprisea lug 301 that is welded to the outer surface 204 of the drum 103. Thecarbide bolster 203 may be press-fit to the lug 301.

FIG. 12 is another cross-sectional diagram of an embodiment of an impacttool 101 disposed on a portion of a drum 103. The drum 103 may comprisea lug 301. The lug 301 may be press-fit into the drum 103. The carbidebolster 203 may be press-fit to the lug 301.

FIGS. 13 and 14 are a perspective diagrams of an embodiment of a tool101. The carbide bolster 203 comprises a bore 302 that may be adapted toreceive a bolt 301 through which the bolster may be attached to thedrum. In some embodiments, the bolt may be threaded as in FIG. 15 wherethe bolt is generally arranged parallel to a central axis 165 of thetool. In other embodiments, the bolt may be threaded to the drum such asin the FIG. 14. FIG. 14 also discloses the bolt positioned at an anglewith respect to the central axis of the tool. The lug 301 may beinserted through the carbide bolster 203 to create a press-fit. The bore302 of the carbide bolster 203 may extend through the carbide bolster203.

FIG. 16 is another cross-sectional diagram of an embodiment of aplurality of tools 101 disposed on a drum 103. The tools 101 maycomprise a carbide bolster 203 attached to super hard material 202 andis press fit onto the outer surface of the drum 103. The carbide bolster203 may comprise a tapered end 1650 opposite the super hard material202. It is believed that such geometry reduces stress risers in theformation which can result in fragmenting the formation. The drum 103comprises a central axle 1601 about which it rotates. The central axlemay comprise an internal accumulator 1602. The accumulator 1602 maycomprise a spring, a filter, and a throw-away filter disc, along with anaccumulator vent. The accumulator 1603 may act as a lubrication system200 comprising oil. The oil lubricates the axle 1651 from the drum 103as it rotates.

FIG. 17 is another cross-sectional diagram of an embodiment of a tool101 disposed on a drum 103. The drum 103 may be part of a rollerassembly 1600 that may comprise tools 101. The tools 101 may comprise acarbide bolster 203 attached to super hard material 202 and is press fitinto the drum 103.

FIG. 18 is another cross-sectional diagram of an embodiment of a tool101 disposed on a portion of a chain 1850, such as a trenching chain.The chain 1850 may comprise a holder 1800 that may be welded to a plate1802 of the chain 1850 which moves in the direction of the arrow 1801.The holder 1800 may comprise a reentrant 1803 which may create acompliant region. This may allow the tool to resist more forces. As thetool travels degrading the formation 104 it carries the formationcuttings with it exposing new formation for engagement with adjacentimpact tools 101.

FIG. 19 is another cross-sectional diagram of an embodiment of a tool101 disposed on a degradation machine 1900. The degradation machine 1900may comprise a plurality of tools 101 adapted to degrade material withina mouth 1901. The machine 1900 may comprise an axle motion which may aidin degrading the material. The machine 1900 may comprise a cam 1902attached to a wall 1903 of the machine 1900. As the cam 1902 moves itmay force the mouth 1901 to close crushing material within the mouth1901. The machine 1900 may comprise a motor 1904 attached to the cam1902 and adapted to control the cam 1902.

FIG. 20 is another cross-sectional diagram of an embodiment of a tool101 disposed on a rotary mill 2000. Material 2001 may enter the rotarymill 2000 where the tool 101 may degrade it. The rotary mill 2000 maycomprise at least one arm 2001. The arm 2001 may comprise at least onetool 101 adapted to degrade the material 2001. The rotary device 2000may also comprise an exit port 2002 where the degraded material mayexit.

FIG. 21 is a cross-sectional diagram of an embodiment of a tool 101disposed on a percussion bit 2100. The percussion bit 2100 may comprisea plurality of lugs 301 adapted to attach to the tool 101. The tool 101may comprise a carbide bolster 203. The carbide bolster 203 may comprisea cavity 302 adapted to attach to the lugs 301. The percussion bit 2100may comprise a plurality of tools 101 that may interlock through atleast one flat 401.

FIG. 22 is another cross-sectional diagram of an embodiment of a tool101 disposed on a percussion bit 2100. The percussion bit 2100 maycomprise a plurality of recesses adapted to receive the tools 101through a press-fit. The tool 101 may comprise a stem 200 adapted tointerlock with the recesses.

FIG. 23 is another cross-sectional diagram of a plurality of tools 101.The carbide bolsters 203 of the impact tools 101 may comprise a circulargeometry 2300, and may be disposed on a target, such as a target 2300for a vertical shaft mill as shown in FIG. 23.

FIG. 24 and FIG. 25 are cross-sectional diagrams of a plurality of tools101. The impact tool may be placed on a vibrating arm, such as a rockbreaker adapted to degrade material. The impact tool 101 may comprise acavity 302 that may be press-fit to the vibrating arm.

The tool may be used in a drill bit 2600, as disclosed in FIG. 26. Thetool may comprise a bore 302 adapted to be press-fit onto the lugs 301of the drill bit 2600. In other embodiments, the tools may beincorporated into roller cone bits, water well drill bits, or othertypes of drill bits.

FIG. 27 is a cross-sectional diagram of a plurality of tools 101attached to a drum. The bolsters may be retained by a head of the shank,which shanks comprise a distal end attached to a hydraulically movablerod. For convenience when it is desirable to replace a bolster thehydraulically movable rod may extend the shank outward allowing easyaccess to the bolster so that it may be replaced.

Whereas the present invention has been described in particular relationto the drawings attached hereto, it should be understood that other andfurther modifications apart from those shown or suggested herein, may bemade within the scope and spirit of the present invention.

1. A tool, comprising; a super hard material bonded to a cemented metalcarbide substrate at a non-planar interface; a cemented metal carbidesubstrate being bonded to a front end of a cemented metal carbidebolster; the carbide bolster being secured against an outer surface of adrum through a press fit.
 2. The tool of claim 1, wherein the substrateat the interface comprises a tapered surface starting from a cylindricalrim of the substrate and ending at an elevated flatted central regionformed in the substrate.
 3. The tool of claim 2, wherein the fattedregion comprises a diameter of 0.125 to 0.250 inches.
 4. The tool ofclaim 1, wherein the bolster comprises a stem with a diameter of 0.250to 1.00 inches.
 5. The tool of claim 4, wherein the stem comprises alength of 35 to 100 percent of the length of the bolster.
 6. The tool ofclaim 1, wherein the drum comprises a lug adapted to attach to thebolster.
 7. The tool of claim 5, wherein the lug is threadedly attachedto the drum and the bolster.
 8. The tool of claim 5, wherein the lug ispress-fit into the carbide bolster.
 9. The tool of claim 5, wherein thelug is press-fit into the drum.
 10. The tool of claim 5, wherein the lugcomprises a hydraulic pump adapted to move the lug and lock the carbidebolster against the drum.
 11. The tool of claim 1, wherein the carbidebolster comprises a base end with a complimentary surface to that of theouter surface of the drum.
 12. The tool of claim 1, wherein the metalcarbide bolsters are interlocked together.
 13. The tool of claim 1,wherein the metal carbide bolsters are interlocked through at least oneflat.
 14. The tool of claim 1, wherein the bolster comprises a stem thatis adapted to be press-fit into the drum.
 15. The tool of claim 1,wherein the bolster comprises at least one bore opposite the front end.16. The tool of claim 15, wherein the bore is tapered.
 17. The tool ofclaim 1, wherein the super hard material comprises a substantiallyconical surface with a side which forms a 35 to 55 degree angle with acentral axis of the tool.
 18. The tool of claim 1, wherein the resistantimpact tool is attached to a milling machine, a mining machine, atrenching machine, or combinations thereof.
 19. A tool, comprising; asuper hard material bonded to a cemented metal carbide substrate at anon-planar interface; the cemented metal carbide substrate being bondedto a front end of a cemented metal carbide bolster; and the metalcarbide bolster comprising a locking mechanism adapted to attach to adrum.